Upgradation of ITIs into Centres of Excellence- Broad guidelines for implementation of Advanced Module of Sector Automobile.

Transcription

1 Upgradation of ITIs into Centres of Excellence- Broad guidelines for implementation of Advanced Module of Sector Automobile. These Centres will be providing multiskill training to meet the skill requirement of particular sector of industry with their active involvement in all aspects of training. The training will be provided in three parts as given below: Training in Basic skill areas for a period of one year. Training in Advanced modules of six months duration after Broad based basic Training(BBBT) Testing & Certification both for the Broad Based Basic Training & Advanced Module Training during subsequent six months will be conducted under the aegis of NCVT. Training in specialized modules mainly by the industry (The course curricula, duration etc will be designed in consultations with the IMC/local industry). The trade testing & certification for specialized module will be done jointly by the State Government & Industry. Said certificate will have recognization from NCVT As per the recommendations of the EFC, Training in the shop floor should constitute alteast 25-40% of the curriculum. The training programme will have multi-entry and multi-exit provisions as given below: trainee can opt to go to the labour market after completing broad based basic training of one year duration or after completing advanced module/s. multi-entry and multi-exit provisions would enable a trainee to take admission for advanced/ additional advanced /specialized module as per his/her need. Guidelines for Training in Advanced modules A minimum of three modules would be essentially needed, so as to ensure that all the 96 trainees are accommodated in the three modules may be selected in consultation with IMC for which in two shifts. If it is felt that available modules for which the course curricula has been developed at National Level are not sufficient to cater to the needs of local industry in a particular state, States are free to select module as per need in consultation with industry. They may develop suitable module(s) accordingly in consultations with the industry clearly indicating tool & equipment list, instructor qualifications, space norms etc. & forward the same to DGE&T for seeking approval of NCVT. A trainee at a time can opt only for one Advanced Module. Admission Criteria, Space requirement, Qualification of instructor of the various modules of Automobile sector are attached herewith. Admission to Advanced Module for the graduates of ITI in related trades: There is a provision for lateral entry for graduates of ITIs (NTC /NAC passed outs from conventional system ) of the related trades subject to availability of seats in Advanced Module. Trades of conventional system mentioned against each advanced module in the enclosed statement, could be offered admission in Advanced Module.

2 MODULE NO. NAME OF THE MODULE Admission criteria Space requirement Duration In Weeks Qualification/Status Of Instructor AAT-01 AAT-02 AAT-03 AAT-04 AAT-05 AAT-06 Servicing & Overhauling of Automobiles (Petrol) Servicing & Overhauling of Automobiles (Diesel); Auto Electrical Electronics & Air-conditioning in Automobiles Overhauling of Fuel Injection System & Steering Denting/Painting & Welding of Automobiles Repair & Maintenance of Wheel ; Re-trading of Tyres & Wheel Balancing Completed BBBT in Automobile Sector OR NTC/NAC in Mechanic Motor Vehicle or other relevant trade OR Diploma in Automobile Completed BBBT in Automobile Sector OR NTC/NAC in Mechanic Motor Vehicle or other relevant trade OR Diploma in Automobile Completed BBBT in Automobile Sector OR NTC/NAC in Mechanic Motor Vehicle or other relevant trade OR Diploma in Automobile Completed BBBT in Automobile Sector OR NTC/NAC in Mechanic Motor Vehicle or other relevant trade OR Diploma in Automobile Completed BBBT in Automobile Sector OR NTC/NAC in Mechanic Motor Vehicle or other relevant trade OR Diploma in Automobile Completed BBBT in Automobile Sector OR NTC/NAC in Mechanic Motor Vehicle or other relevant trade OR Diploma in Automobile 100 sq m with Separate parking space for each modules. 24 weeks Degree in Automobile Engg with minimum two years teaching/industrial experience in the relevant field OR Diploma in Automobile Engg with min four years teaching/industrial experience in the relevant field. 2

3 UPGRADATION OF ITIs into CENTERS of EXCELLENCE (CoE) ADVANCED MODULES IN II YEAR ( FOR THE FIRST 6 MONTHS OF II YEAR ) 3

4 I N D E X UPGRADATION OF ITIs INTO CENTRES OF EXCELLENCE ( CoE ) ADVANCED MODULES IN II YEAR ( FOR THE FIRST 6 MONTHS OF II YEAR ) MODULE NO. NAME OF THE MODULE DURATION IN WEEKS PAGE NO. AAT - 01 SERVICING & OVERHAULING OF AUTOMOBILES ( PETROL ) 26 weeks AAT - 02 SERVICING & OVERHAULING OF AUTOMOBILES ( DIESEL ) - do AAT - 03 AUTO ELECTRICALS, AUTOELECTRONICS & AIRCONDITIONING IN AUTOMOBILES - do AAT - 04 OVERHAULING OF FUEL INJECTION SYSTEM & STEERING MECHANISM - do AAT - 05 DENTING PAINTING & WELDING - do AAT - 06 REPAIR & MAINTENANCE OF WHEEL, RE TREADING OF TYRES & WHEEL BALANCING - do te : The trainees promoted / passed BBBT are eligible for these second year specialized modules. Trainee has to select ANY ONE ONLY out of these specialized modules 4

5 MODULE AAT - 01 : SERVICING & OVERHAULING OF AUTOMOBILES ( PETROL ) ( Duration - 26 weeks ) I) COURSE CONTENT Practical Identification of vehicle components. Compression pressure test & its importance Removing & refitting of petrol engine from vehicle. Dismantling of petrol engine. Removing broken studs. Servicing of inlet, exhaust manifold. Overhauling of piston and connecting rod assembly. Complete overhauling of petrol engine. Assembling engine parts, piston connecting rod, cylinder head. Rocker arm assembly, manifold and other accessories of the petrol engine. Setting of valve timing & adjusting tappet clearance on different engines. Turning of engine and testing the performance f th t l i Theory General classification of petrol engine vehicle Main parts of vehicle (body & chassis) Classification of chassis & frame Power generation system(engine): Description, construction and functions of petrol engine parts. Important working parts in the engine the two stroke & four stroke cycle, single & multicylinder, horizontal, vertical & inclined engine. Moving parts such as piston rings, piston, connecting rod, piston pin, cam shaft, crank shaft valve lifter, valve operating mechanism and valve timing. Description and functions of valves, valve spring, valve seat, valve guide, tappet clearance & stationary parts - cylinder head, cylinder liner (wet & dry) & cylinder block. Main bearings, crank case and oil sump. Power generation system(engine):introduction of carburetor & its circuit, distributor & its parts, vacuum advance, spark plug, ignition coil. Types of Air cleaners, filters, superchargers, firing order. Inspection & measurement of engine head, engine block, cam shaft, crank shaft & other moveable parts, valve timing diagram, purpose of oil galleries & water jackets, combustion chambers of petrol engine. Description & operation of multipoint fuel injection system. Study and adjustments of engines fitted with CNG/LPG kit. Study of euro III norms and its effect on the performance of an engine. Cooling System: Purpose of cooling system. Types of cooling system. water cooling system 5

6 of the petrol engine. Adjustments, troubleshooting and remedies of CNG/LPG system fitted on engines. Servicing of water pump and testing thermostat valve. Servicing of radiator and adjusting fan belt. Servicing of oil pump. and its parts. Radiator, water pump. Thermostat valve. Anti fizzers, coolants, radiator pressure cap. Lubricating system: Types of Lubricating system and use of its parts, oil classification, types of oil pumps its drive, oil filter, drive system its parts, oil cooling in petrol engine. Application of synthetic oil. Practical Theory Transmission Unit: Overhauling of clutch assembly of vehicle. Overhauling of gear box of vehicle. Overhauling of differential, servicing of propeller shaft. Testing of transmission alignment. CLUTCH ASSEMBLY: Requirement of a clutch, types of clutch, main parts of clutch, clutch plate, clutch lining, pressure plate, pressure spring, clutch pedal, clutch release bearing, fork, single plate, cone clutch, centrifugal clutch, diaphragm clutch, fluid fly wheel. GEAR BOX ASSEMBLY: Purpose of gearbox, types of gear box, synchromesh gear box, constant mesh gearbox, epicyclic gear box, parts of gearbox, types of gears, counter shaft, transmission shaft, gear lever, gear shifter fork. Introduction on Torque Convertors. PROPELLER SHAFT & DIFFERENTIAL ASSEMBLY: Description & purpose of different types of- propeller shaft, universal joint, slip joint or sliding joint. Differential & rear axles, front wheel drive and rear wheel drive. Differential lock. Different types of bearings - roller type, ball bearing, taper roller bearings. Overhauling of brake in vehicle. Suspension System: Functions of suspension system, independent front suspension, torsion bar, leaf spring, stabilizer, types of suspension springs, different types of shock absorbers their description. 6

7 Bleeding of hydraulic brake. Repair & Maintenance of tyre and tubes. Adjusting wheel alignment & wheel balancing. Repair & Maintenance of body of vehicle. Servicing of steering system Control unit: STEERING SYSTEM: Description of different types of steering boxes manual, hydraulic and electrics. Special features of each, adjustments. Power Assisted steering and advantages. Description of ackermans angle, caster, camber, King pin Inclination, Toe-in, & toe-out, toe-out on turn and purpose and effect of these angles. Steering linkage system, four wheel steering (4 WS). Need of front wheel alignment. BRAKE SYSTEM: Types of brakes, functions, description and advantages of vacuum assisted hydraulic brakes, common troubles in vacuum assisted hydraulic brake. Classification of brakemechanical brakes & parking brake. Power assisted brake, working of wheel cylinder and master cylinder. Function and working of antilock braking system. Servicing of fuel supply system & servicing of air cleaners. Servicing of carburetor Fuel Supply System: Purpose of fuel supply system, Types & function of carburattors. Types of fuel pump- AC Mechanical fuel pump and electrical fuel pump. Force feed system, fuel filter. Function and working of fuel injection system. Performance of engine to save fuel and energy. Ignition System: Description of spark ignition system. Distributor, vacuum advance, condenser, C.B. Point, air fuel ratio. Electronic Distributerless Ignition System. Starting and stopping of petrol engine. Trouble shooting of petrol engine. Trouble in electrical circuits. Testing of electronic devices used in petrol engine. Electrical & Electronic Unit: Description of electrical circuits ignition system and components. Purpose of induction coils, condenser, spark plugs. Description of charging circuits operation of alternator. Introduction to electronic, definition of resistor, capacitor and inductor and their principles of working. Different types of diodes, transistors, power supply for electronic circuit. Function of sensor and electronic control module/unit (ECM/ECU). II) OBJECTIVE: 7

8 Classification of petrol engine vehicle Identify the main parts of petrol engine Explain the functions of carburetor Explain the functions of distributor Describe the different types of drive and gear box use Carry out the routine check up of petrol engine before starting Knowledge of fuel & oils Energy & fuel saving tips Dismantling, repair, maintenance and overhauling of petrol engines. Repair, maintenance and overhauling of different systems of an automobile. III) ACHIEVEMENT After completion of Course, the trainee will be able to: to dismantle and re-assemble the petrol engine of vehicle. to identify the parts of petrol engine. to know about the preventive maintenance of petrol engine vehicle. To know overhauling of petrol engines To know repair, maintenance and overhauling of different systems/assemblies of petrol vehicle. te: This will include driving practice of M-Car and LCV for two weeks and issue of license from transport authority. IV) TOOLS, MACHINERY, EQUIPMENTS etc. for a batch of 16 trainees 8

9 Sl Item Qty Sl Item Qty a) TRAINEES TOOL KIT 09 Hand file 20 cm. Second cut flat 17 s 01 Steel rule 15 cm. English and metric 17 s 10 Hand file 20 cm. Second cut half-round 17 s 02 Screw driver 20cm.X 9mm. Blade 17 s 11 Hand file 20 cm. smooth triangular 17 s 03 Screw driver 30 cm. X 9 mm. Blade 17 s 12 Hand file 30 cm. bastard 17 s 04 Spanner D.E. set of 12 pieces (6mm to 32mm) 17 s 13 Hand file 30 cm. round bastard 17 s 05 Pliers combination 20 cm. 17 s 14 Centre punch 10 cm. 17 s 06 Pliers side cutting 15 cm 17 s 15 Chisel cold flat 20 mm. 17 s 07 Plier round nose 15 cm 17 s 16 Feeler gauge 20 blades (metric) 17 s 08 Plier flat nose 15 cm 17 s 17 Steel tools box with lock and key (folding type) size 400X200X150mm 17 s b) SHOP OUTFIT & MEASURING INSTRUMENTS 40 Spanner, adjustable 15cm Hollow punch set of seven pieces 6mm to 15mm 1 Set. 41 Spanner for spark plugs 14mm. 2 s. 19 Drift punch copper 15 cm 2 s. 42 Spanners socket with speed handle, T-bar, ratchet and 2 sets universal upto 32 mm set of 28 pieces with box 20 Prick punch 15 cm. 2 s. 43 Adjustable spanner (pipe wrench 350 mm) 2 s. 21 Chisels cross cut 200 mm X 6mm 2 s. 44 Chain and pulley block 3000 kg. Capacity electric type Allen Key set of 12 pieces (2mm to 14mm) 04Sets 45 Horses and wheel choke 4 Sets 23 Philips Screw Driver set of 5 pieces (100 mm to 300 mm) 04Sets 46 Screw jack one tone, capacity double lift 2 s. 24 Rule steel 30 cm. English and metric 2 s. 47 Hydraulic jack with trolley capacity 3 Ton Engineer s square 15 cm. Blade 2 s. 48 Oil can 0.5/0.25 liter capacity Dividers spring 15 cm. 2 s. 49 Cleaning tray 45x30 cm. 4 s. 27 Ball peen Hammer 0.5kg. 16 s. 50 Piston ring expander and remover 50 mm & 100 mm 1 each 28 Scriber with scribing black universal Piston Ring compressor 2 s. 29 Marking out table 90X60X90 cm. 1 s. 52 Piston Ring Groove cleaner 2 s. 30 Hacksaw frame adjustable Cylinder ridge remover/cutter Engineers stethoscope 1 s. 54 Torque wrench 5 to 35 Nm, Nm & Nm Hand vice 37 mm 2 s. 55 Work bench 250 x 120 x 60 cm with 2 vices 12cm Jaw 2 s. 33 Drill Twist (assorted) 10 s 56 Pullers screw powered 2 mm gap with bearing puller 1. attachment 34 Taps and Dies complete sets (5 types) 1 set 57 Vice grip pliers 2 s. 9

10 each 35 Hand reamers adjustable 10.5 to mm, to Sets 58 Circlip pliers Expanding and contracting type 15cm and 8 Sets. mm, to mm and to mm 20cm each 36 Micrometer out side 0-25 mm, mm, mm, mm 1 each 59 Inspection lamp with guard and wandering lead of 100ft. length Micrometer in side 25-50, 50-75, mm with extension 1 each 60 Crow bar 1. rod. 38 Mallets wooden/plastic. 2 s. 61 Fire extinguisher ABC type 5 kg capacity. 2 s. 39 Spanner, ring set of 12 metric sizes 6 to 32 mm. 2 s. 62 Fire Buckets (4 s.) with stand 2 s. Sl Item Qty Sl Item Qty 63 Feeler gauge piston (metric) 1 Set 85 Disk brake with caliper assembly 2 s. 64 Cleaning tray- Aluminum 45 x 30 cm 8 s. 86 Tandem master cylinder with booster 4 s. 65 Spark plug spanner 14mm x 18mm x Size 2 s. 87 Wheel cylinder 4 s. 66 Valve spring lifter Lead acid battery 12 V 4 s. 67 valve grinding tool-suction type 6 s. 89 Battery charger 6 24 V with 10 A rate Valve seat cutting tools complete with guides and pilot bar (all angles) 1 Set. 90 C.V. Joint units of 3 different types 4 sets 69 Valve key inserter Drilling machine bench to drill up to 12mm die Cylinder bore gauge capacity 20 to 160 mm 2 s. 92 Electric pedestal grinder with two 18cm. Wheel Carburetor 2 s. 93 Compression testing gauge to read 0 to 50 kg/sq.cm Fuel feed pump 2 s. 94 Vacuum gauge to read 0 to 760 mm of Hg Circlip pliers 15 cm. Expanding type Cut model of 4 stroke Petrol engine on stand Circlip pliers 15 cm. Contracting type Cut model of 2 stroke Petrol engine on stand 1. c) GENERAL INSTALLATION / MACHINERIES 97 Engine analyzer 1 Sets. 76 Straight edge gauge 2 ft Bearing puller screw powered/hydraulic powered with attachments Max spread 80, 200 and 300mm 77 Distributor 2 s. 99 Speed counter / Tacho meter pointed type to read up to 5000 RPM 78 Surface Plate 60 x 60cm Petrol Engine of: latest model ( CNG Engine ) with workshop manuals 1 Each

11 79 V Block 75 x 38mm pair with Clamps 2 s. 101 Petrol engine 4 stroke fitted with MPFI/carburetor fuel 2s. system for practice, up to 50 H.P. with manuals 80 4 Wheeler petrol vehicle fitted with MPFI Spark plug testing machine 1. system/carburetor system with manuals 81 Synchromesh gear box of LCV 2 s. 103 Smoke testing machine Diapragm type clutch assembly 2 s. 104 Petrol Engines of cars of latest models with manuals Drum brake assembly 2 s. 105 Triple leg grip puller with bearings attachment screw/ hydraulic Powered max. spread 80, 160, 250, 450 mm 1. te : Item. 1 to 10 is to be procured in case training in module. 06 is not being imparted in the Institute. Item. 11 is to be procured in case training in module. 03 is not being Imparted in the Institute. NOTE : 1 Tube vulcanizing machine 1. 2 Tyre remover pneumatic & mechanical type 1 set 3 Tyre vulcanizing machine 1. 4 Air compressor with accessories 1. 5 Tyre pressure gauge with accessories 1 set 6 Wheel alignment gauge 1 set 7 Camber angle gauge 1. 8 Toe-in, toe-out gauge 1. 9 Wheel balancing machine with accessory 1 set 10 Tubed tyre of cars 2 each 11 Electronic engine control module 1. All the tools and equipment etc should be Latest available in the Market Workshop furniture Qty Suitable Work Tables with vices As required. Stools 17 s Discussion Table 1 Tool Cabinet 2 s Trainees locker 2 s Fire fighting equipment, first aid box etc As required Book shelf ( glass panel ) 1. Storage Rack As required Storage shelf As required 11

12 UPGRADATION OF ITIs into CENTERS of EXCELLENCE (CoE) ADVANCED MODULES IN II YEAR ( FOR THE FIRST 6 MONTHS OF II YEAR ) MODULE AAT - 02 : SERVICING & OVERHAULING OF AUTOMOBILES ( DIESEL ) ( Duration - 26 weeks ) I) COURSE CONTENT 12

13 Practical Theory Compression pressure test & its importance. Removing & refitting of diesel engine from the vehicle. Dismantling of diesel engine. Servicing of inlet, exhaust manifold. Removing broken studs. Overhauling of engine block, crank shaft, cam shaft, cylinder head, piston & connecting rod assembly General classification of diesel engine vehicle Main parts of Automobiles (Body & Chassis) Classification of Chassis & frame Body (Full & half body vehicle) Power Generation System: Description, construction and function of engine parts, important working parts in the engine, the four stroke cycle, piston rings, piston connecting rod, cam shaft, crank shaft, valve lifter, valve operating mechanism and valve timing. Description and function of valve, valve seat, valve seals, tappet clearance in four and six cylinder engines. Cylinder Head, cylinder liners( wet & dry), cylinder block, big end & Main Journal bearings, crank case and oil sump. Servicing of water pump and testing thermostat valve. Servicing of radiator and adjusting fan belt. Servicing of oil pump. Assembling engine parts, piston connecting rod, cylinder head. Rocker arm assembly, manifold and other accessories of the car engine. Setting valve timing & adjusting tappet clearance. Starting and stopping of diesel engine. Trouble shooting of diesel engine. Tuning of engine for better performance. Power Generation System: Type of air cleaners. Different types of filters, firing order, turbo chargers. Working of exhaust gas recirculation & its purpose. Cooling System: Purpose of cooling system. Types of cooling system - Air cooling system and water cooling system and its parts. Radiator, water pump. Thermostat valve. Anti freezers, coolants & radiator pressure cap. Lubricating system: Types & purpose of Lubricating system, oil classification, types of oil pumps its drive, oil filter, drive system its parts, oil cooling in diesel engine. 13

14 Practical Theory Servicing fuel supply system, servicing of air cleaners. Overhauling fuel feed pump. Bleeding of fuel supply system. Phasing & calibration of F.I.Pump. Setting fuel injection pump timing. Fuel Supply System: Types of fuel injection system ( DI & IDI, CRDI ), types of combustion chambers and glow plugs. Purpose of fuel supply system, types of fuel pump. Mechanical fuel feed pumps ( plunger type, vane type & gear type ) and electrical fuel feed pump. Fuel filter. Function and working of injectors and inline fuel injection pump and their parts. Procedure for phasing & calibration. Types of governors & their working principles. Distributor type pump. Transmission Unit: Overhauling of clutch assembly. Overhauling of gear box. Testing of transmission alignment. Overhauling of differential, servicing of propeller shaft. CLUTCH ASSEMBLY: Types & Requirement of a clutch, main parts of clutch, clutch plate, clutch lining, pressure plate, pressure spring, clutch pedal, clutch release bearing, slave cylinder, single & multi plate clutch & cone clutch. GEAR BOX ASSEMBLY: Purpose of gearbox, types of gear box, synchromesh gear box, constant mesh gearbox, epicyclic gear box, parts of gearbox, types of gears, counter shaft, transmission shaft, gear lever, gear shifter fork. Introduction of Torque convertor. PROPELLER SHAFT & DIFFERENTIAL ASSEMBLY: Description & purpose of different types of rear axles propeller shaft, universal joint, slip joint or sliding joint. Differential, its purpose, front wheel drive and rear wheel drive. Differential lock. Different types of bearings - roller type, ball bearing taper roller bearing. Practical Theory 14

15 Control Unit: Servicing of steering system. Overhauling of brake system. Bleeding of hydraulic brake. Repair & Maintenance of tyre and tubes. Wheel balancing & alignment. STEERING SYSTEM: Description of different types of steering boxes special features of each, adjustments. Power assisted steering description and its advantages. Description of ackermans angle, caster, camber, Toe-in, toe out, toe-out on turn, king pin inclination - purpose and effect of these angles. Steering linkage system, four wheel steering ( 4 WS ). Need of front wheel alignment. BRAKE SYSTEM: Functions of different types of brakes and its parts. Description and advantages of vacuum assisted hydraulic brakes, common troubles in vacuum assisted brakes & air brake. Working of wheel cylinder and master cylinder. Suspension System: Functions of suspension system, independent front suspension, torsion 3333bar, leaf spring. Type of shackle pin and fixing assembly. Shock absorbers (single and double acting type). Front Axle - Different types of stub axle, construction of front axle. Function of front axle system. Ball joint axle beam. Overhauling of alternators Overhauling of starter & wiper motor Maintenance of Battery Regulator setting Testing of glow plugs Electrical & Electronic Unit: Description of electrical circuits starter motors & glow plugs. Description of charging circuits operation of alternator. Introduction to electronic, definition of resistor, capacitor and inductor and their working principles. Different types of diodes, transistors, power supply for electronic circuit. II) OBJECTIVE: 15

16 To study the classification of diesel engine vehicle To dismantle the diesel engine and checking of different assemblies To assemble engine assemblies after overhauling To learn various types of chassis To learn the suspension system To learn various types of front axle To dismantle and assemble transmission system. To learn servicing of brake system To dismantle and assemble steering system. III) ACHIEVEMENT After completion of Course, the trainee will be able to: Overhaul the complete diesel engine Vehicle Testing of performance of engine after overhauling Overhauling of clutch and gear box Checking and repair of different systems of diesel vehicle Diagnosing troubles in fuel injection system and its remedies Check & inflate tyre pressure Check & bleed hydraulic brake system te: This will include driving practice of M-Car and LCV for two weeks and issue of license from transport authority. IV) TOOLS, MACHINERY, EQUIPMENTS etc. for a batch of 16 trainees 16

17 Sl Item Qty Sl Item Qty a) TRAINEES TOOL KIT 21 Chisels cross cut 200 mm X 6mm 2 s. 01 Steel rule 15 cm. English and metric 17 s 22 Allen Key set of 12 pieces (2mm to 14mm) 04Sets 02 Screw driver 20cm.X 9mm. Blade 17 s 23 Philips Screw Driver set of 5 pieces (100mm to 300 mm) 04Sets 03 Screw driver 30 cm. X 9 mm. Blade 17 s 24 Rule steel 30 cm. English and metric 2 s. 04 Spanner D.E. set of 12 pieces (6mml to 32mm) 17 s 25 Engineer s square 15 cm. Blade 2 s. 05 Pliers combination 20 cm. 17 s 26 Dividers spring 15 cm. 2 s. 06 Pliers side cutting 15 cm 17 s 27 Ball peen Hammer 0.5kg. 16 s. 07 Plier round nose 15 cm 17 s 28 Scriber with scribing black universal Plier flat nose 15 cm 17 s 29 Marking out table 90X60X90 cm. 1 s. 09 Hand file 20 cm. Second cut flat 17 s 30 Hacksaw frame adjustable Hand file 20 cm. Second cut half-round 17 s 31 Engineers stethoscope 1 s. 11 Hand file 20 cm. smooth triangular 17 s 32 Hand vice 37 mm 2 s. 12 Hand file 30 cm. bastard 17 s 33 Drill Twist ( assorted ) 10 s 13 Hand file 30 cm. Round bastard 17 s 34 Taps and Dies complete sets ( 5 types ) 1 set 14 Centre punch 10 cm. 17 s 35 Hand reamers adjustable 10.5 to mm, to 2 Sets mm, to mm and to mm 15 Chisel cold flat 20 mm. 17 s 36 Micrometer out side 0-25 mm, mm, mm, 1 each mm 16 Feeler gauge 20 blades (metric) 17 s 37 Micrometer in side 25-50, 50-75, mm with 1 each extension rod. 17 s 38 Mallets wooden/plastic. 2 s. 17 Steel tools box with lock and key (folding type) size 400X200X150mm b) SHOP OUTFIT & MEASURING INSTRUMENTS 39 Spanner, ring set of 12 metric sizes 6 to 32 mm. 21 sets. 18 Hollow punch set of seven pieces 6mm to 15mm 1 Set. 40 Spanner, adjustable 15cm Drift punch copper 15 cm 2 s. 41 Spanners socket with speed handle, T-bar, ratchet and 2 sets. universal upto 32 mm set of 28 pieces with a box 20 Prick punch 15 cm. 2 s. 42 Adjustable spanner ( pipe wrench 350 mm) 2 s. Sl Item Qty Sl Item Qty 17

18 43 Chain and pulley block 3000 kg. Capacity electric type Portable electric drill 6mm Horses and wheel choke 4 s. 67 Circlip pliers 15 cm. Expanding type 1. each 45 Screw jack one tone, capacity double lift 2 s. 68 Circlip pliers 15 cm. Contracting type Hydraulic jack with trolley capacity 3 Ton 1. c) GENERAL INSTALLATION / MACHINERIES 47 Oil can 0.5/0.25 liter capacity Fuel feed pump Cleaning tray 45x30 cm. 4 s. 70 Injectors 2 s. 49 Piston ring expander Surface Plate 60 x 60cm Piston Ring compressor 2 s. 72 V Block 75 x 38mm pair with Clamps 2 s. 51 Piston Ring Groove cleaner 2 s. 73 Drilling machine bench to drill up to 12mm die Cylinder ridge remover/cutter Electric pedestal grinder with two 18cm. Wheel Torque wrench 5 to 35 Nm, Nm & Nm 1 each 75 Compression testing gauge to read 0 to 115 kg/sq.cm Work bench 250 x 120 x 60 cm with 2 vices 12cm Jaw 2 s. 76 Vacuum gauge to read 0 to 760mm of Hg Pullers screw powered 2 mm gap with bearing puller attachment Fuel injection pump - pneumatic governor, R.Q. V. governor and R.S.V. governor 2 s. each 56 Vice grip pliers 2 s. 78 Disk brake with caliper assembly 2 s. 57 Circlip pliers Expanding and contracting type 15cm and 20cm 8 Sets. 79 Valve seat cutting tools complete with guides and pilot 1 Set. each bar (all angles) 58 Inspection lamp with guard and wandering lead of 50ft. length Bearing puller screw powered/hydraulic powered with attachments Max spread 80, 200 and 300mm 1 Each. 59 Crow bar Straight edge gauge 4 ft Feeler gauge piston (metric) 1 Set 82 4 Wheeler diesel vehicle different models 2 s. 61 Cleaning tray- Aluminum 45 x 30 cm 8 s. 83 Synchromesh gear box of LCV 2 s. 62 Valve spring Lifter Gear box with differential ( Transaxle ) Valve grinding tool- suction type 6 s. 85 Diapragm type clutch assembly 2 s. 64 Valve key inserter Drum brake assembly 2 s. 65 Cylinder bore gauge capacity 20 to 160 mm 2 s. 87 Tandem master cylinder with booster 4 s. Sl Item Qty Sl Item Qty 18

19 88 Diesel engine 4 stroke for practice, up to 80 H.P. 4 s. 95 Injector tester (hand operated) Wheel cylinder 4 s. 96 Injector dismantling jig with mounting bench Lead acid battery 12 V 4 s. 97 Fuel injector cleaning kit (in a wooden box complete) 4 Sets. 91 Battery charger 6 24 V with 10 A rate Tachometer pointed type to read up to 5000 RPM C.V. Joint units of 3 different types 4 sets 99 Cut model of 4 stroke diesel engine on stand Diesel Engines of latest models of vehicles 2 s. 100 Triple leg grip puller with bearings attachment screw/ hydraulic Powered maximum spread 80, 160, 250, mm 94 Diesel engine 4 stroke up to 10HP/80HP running condition 1. te : The following tools and equipments are not to be procured if available for other modules/trades in the Institute. Procurement of item. 11 is optional and trainees may be taken to nearby industry for practicals in case the equipment is not procured. 1 Tube vulcanizing machine 1. 2 Tyre remover pneumatic & mechanical type 1 set 3 Tyre vulcanizing machine 1. 4 Air compressor with accessories 1. 5 Tyre pressure gauge with accessories 1 set 6 Wheel alignment gauge 1 set 7 Camber angle gauge 1. 8 Toe-in, toe-out gauge 1. 9 Wheel balancing machine with accessory 1 set Tubed tyre of cars 2 each Fuel injection pump test bench with accessories 1. NOTE : All the tools and equipment etc should be Latest available in the Market Workshop furniture Suitable Work Tables with vices Stools Qty As required. 17 s 19

20 Discussion Table 1 Tool Cabinet 2 s Trainees locker 2 s Fire fighting equipment, first aid box etc As required Book shelf ( glass panel ) 1. Storage Rack As required Storage shelf As required 20

21 UPGRADATION OF ITIs into CENTERS of EXCELLENCE (CoE) ADVANCED MODULES IN II YEAR ( FOR THE FIRST 6 MONTHS OF II YEAR ) MODULE AAT - 03 : AUTO ELECTRICALS, AUTO ELECTRONICS & AIR CONDITIONING IN AUTOMOBILES ( Duration - 26 weeks ) 21

22 I) COURSE CONTENT Practical Theory Measuring Voltage, current, resistance in different circuits in a vehicle. Battery electrolyte preparation, charging and testing Circuit tracing in a vehicle horn circuit, brake lamp circuit, wiper motor circuit, indicators and npower windows circuits. Overview on electrical power, electric charge, factors affecting on resistors, types of resistors/thermisters (PTC & NTC) and calculating effective resistance in different circuits. Methods of generating voltage through electro chemical process, battery constructions and working principle, battery rating and testing and maintenance through induction using light - using the distortion of crystals hall effect principle construction and working principle of oxygen sensor Symbols, colour codes and cable specifications used in wiring diagram. Method of circuit tracing Checking of circuit breakers and relays Construction of simple circuit by using relay Charging system tests alternator output voltage, circuit voltage drop, trouble shooting in a charging system. Dismantling alternators and components tests diodes, rotor condition, rotor winding insulation rotor condition. Circuit protectors. Magnetism temporary and permanent magnet, magnetic fields and magnetic reluctance. Electromagnetism, forming a conductor into a coil and lowering the reluctance of the coil. Electromagnetic devices: Types of relays, solenoids, transformers, parts of alternator Working principle of alternator, rectifier, electronic regulator and checking procedure 22 Practical Theory 22

23 Tracing starter circuit in a vehicle Checking starter motor diagonise the faults Dismantling starter and checking of each components Repairing the faults, assembling and checking starter motor on a test rig. Checking spark plugs, HT leads, ignition coil and condenser Setting ignition timing. Components of starting system circuit starting and ignition systems. Starter construction/design and operation. Components of starter motor armature, field coils, brushes, drive assembly/mechanism, solenoid and overrunning clutch Starter motor performance check procedure Coil ignition system and procedure for setting ignition timing. Spark plug types and construction Radio interference suppression. Checking ignition coil of E-DIS (Electronic Distributorless Ignition system) Checking ground connection Checking sensors using engine scanner and DMM Checking actuators using engine scanner and DMM Construction of simple electronic circuits Checking the different modes/strategies of ECA (Electronic Control Assembly) Resetting of keep alive memory/eca Overview of operation, symbols and checking procedure of diodes, transistors, capacitors and their applications in automobiles. Working E-DIS ( Electronic Distributorless Ignition system ) Importance of earthing Working principle of instruments and gauges Working principle of sensors throttle position (Potentiometer), Air temperature ( Thermistor ), Engine coolant temperature, manifold absolete pressure (Piezo-resistive & Piezo-electric type), Camshaft and crank shaft position sensors ( magnetic pick up type ) Construction and working principle of actuators idle air control valve and injectors Basic structure and operation of a microcomputer Explanation of simple electronic circuits Different strategies/modes available in the ECA Practical Theory AIR CONDITIONING Fundamentals of air conditioning 23

24 Fault finding Dismantling Rectification Refrigeration cycles, simple air condition circuit diagram Gases used for air conditioning & their characteristics & applications Air conditioning system & components AIR CONDITIONING Assembling Testing Effect of air conditioning on fuel economy Air distribution of air conditioning system Compression system used for vehicle air conditioning Fault finding & rectification in vehicle air conditioning II) OBJECTIVE: To learn about lighting circuits and starting circuits & its parts To study the working/operation of horn To locate the wiring circuit of vehicle To dismantle, inspect, assemble & test the Horn To dismantle, inspect, assemble & test the Dynamo To dismantle, inspect, assemble & test the Alternator To dismantle, inspect, assemble & test the Solenoid To dismantle, inspect, assemble & test the Starter & wiper Motors Basic electronic devices Types of simple electronic circuits Use of simple instruments for electronic measurements Application of electronics in modern automobile To learn the maintenance of battery To learn about the automobile air conditioning system 24

25 To learn about components of air conditioning To learn about effects of air-conditioning To learn about the installation, adjustment & repair of automobile air condition. III) ACHIEVEMENT After completion of Course, the trainee will be able to: Trace & locate the fault in wiring circuit Set the ignition timing Repair of alternator & starter motor know wiring circuit of vehicle know & rectify the faults of vehicle air condition Dismantle & assemble vehicle air condition system IV) TOOLS, MACHINERY, EQUIPMENTS etc. for a batch of 16 trainees 25

26 Sl Item Qty Sl Item Qty a) TRAINEES TOOL KIT 23 Flat File 35 cm bastard 2 s 01 Ball Peen Hammer 0.75 Kg 17 s 24 Flat File 25 cm second cut 2 s 02 Cold Flat Chiesel 19mm 17 s 25 Micrometer Outside 0-25mm, 25-50mm 1 each 03 Centre Punch 10 mm dia x 100mm 17 s 26 Soldering iron 120 watts 2 s 04 Insulated Screw driver 30 cm x 9mm blade 17 s 27 se Pliers ( round and straight) 150 mm and 200mm 2 each 05 Insulated Screw driver 20 cm x 9mm blade 17 s 28 Circlip pliers 1 no. 06 Steel rule 30mm 17 s 29 Thread pitch gauge 1 no. 07 Plier combination 15cm 17 s 30 Stud remover 1 no. 08 Steel tool box with lock & key ( folding type ) size 17 s 31 Spanner T. flocks for screwing up and up-screwing x200x150mm inaccessible positions 09 Hand file 20 cm second cut 17 s 32 Cleaning tray 45 x 30cm 16 s 10 Ring spanner set of 12mm 17 s 33 Oil cane 0.5 litres 1 b) SHOP OUTFIT & MEASURING INSTRUMENTS 34 Smp ( straight & bent ) 1 11 Electric testing screw driver 4 s 35 General purpose puller 1 set 12 Hand vice 37 mm 2 s 36 Stud extractors 1set 13 Allen key set of 12 pieces ( 2mm 14 mm) 4 sets 37 Poker 2 s 14 Circlip plier (External and Internal) 150mm & 200mm 8 sets 38 Double ended Spanner 6 to 32 mm - set of 12 nos. 1 set 15 Philips Screw Driver set of 5 pieces 100mm 300mm 4 sets 39 Double ended off-set Spanner(W.W) 3 to 13.5 mm - 1 set set of 7 nos. 16 Star Allen key 4 sets 40 Double open ended ignition spanner set (of BA-0 x 1to 1 set 8x9 set of 5) 17 Prick punch 15 cm 2 s 41 Spanner Clyburn 15 cm Chisel cross cut 200mm x 6 mm 1 42 Adjustable spanner 20 cm Ball Peen Hammer 0.5 Kg 2 s 43 Spark plug spanner 14 mm Hammer copper 1 Kg with handle 1 44 Magneto spanner set with 8 spanners 1 set 21 Hack saw frame for 30 cm blade 4 s. 45 Socket spanner set with handle, T-bar and ratchet 2 s. 22 Hollow punch 6,7,8,9,10 and 12 mm set 1 set 46 Drift copper (10 mm x 150 mm) 1. Sl Item Qty Sl Item Qty 47 Double open ended spanner set (10.5mm x 12 mm; 10.5mm 1 set 70 Starter motor axial type, pre-engagement type & Co- 1 each 26

27 x 18 mm set of four) axial type 48 Hydrometer 2s 71 Electrical horn( different types ) 2 each 49 Spring tension tester 1 no. 72 Wiper motor assembly 4 s 50 A.V.O. meter 1 no. 73 Engine Scanner Alternator regulator tester 1 74 Anti theft device 2 s 52 Distributor tester 1 75 Melting pot 2 s 53 Continuity meter 1 76 Paraffin pressure Gun Clip on meter Digital and Analog 1 each 77 Grease Gun Tachometer 1 78 Pulley set universal for bearing & bushes ( set ) 1 56 Spark Plug tester NEON type Pulley puller 2s 57 High rate discharge tester 1 80 Glow plug 4 nos. 58 Multimeter digital and Analog 1 each 81 Alternator 1 no. 59 Starter motor, alternator, dynomo cut out 2 each 82 Glow plug tester 1 no. c) GENERAL INSTALLATION / MACHINERIES 83 Torque wrenches 5035 Nm, Nm 1 each 60 Drilling Machine ( Bench) 12 mm dia 1 84 Starter test bench 1 no. 61 Growler 1 85 Dynamo and voltage regulator 1 no. 62 Battery charger 6V 24 V 1 86 Alternator and inbuilt regulator 2 nos. 63 AC alternator slip ring puller 1 no 87 Horn and Horn relay 1 each 64 AC alternator slip ring press tool 1 88 Air conditioned MPFI vehicle with accessories 1 no. 65 Executive Auto Electrical tool kit 1 89 Engine control sensors 8 types 2 each 66 Electrical test bench Point relays 4 nos 67 Car stereo Point relays 4 nos 68 Battery 12V (Lead acid & Alkaline) 2 each 92 Bearing puller set ( mm for extracting both outer 2 sets and inner races with box containing (a) 8 internal extractors (b) 2 counter stays (c) Pulling chuck of capacity 5 x 32 mm (d) 2 arm cooler, capacity 80 and 160 mm (e) Slide hammer 69 Electronic engine control module 1 no NOTE : All the tools and equipment etc should be Latest available in the Market Workshop furniture Suitable Work Tables with vices Qty As required. 27

28 Stools 17 s Discussion Table 1 Tool Cabinet 2 s Trainees locker 2 s Fire fighting equipment, first aid box etc As required Book shelf ( glass panel ) 1. Storage Rack As required Storage shelf As required 28

29 UPGRADATION OF ITIs into CENTERS of EXCELLENCE (CoE) ADVANCED MODULES IN II YEAR ( FOR THE FIRST 6 MONTHS OF II YEAR ) 29

30 MODULE AAT - 04 : OVERHAULING OF FUEL INJECTION SYSTEM & STEERING MECHANISM I) COURSE CONTENT ( Duration - 26 weeks ) Practical Theory Dismantle & inspect part of fuel feed pumps Assemble & test of fuel feed pumps Dismantle fuel filter assembly Replace filter elements Bleed fuel supply system Types of fuels Specification of fuel Function & working of fuel supply system with fuel system layout Types of filter elements Function & working of plunger type feed pump, AC pump Dismantle the FI Pump Clean & inspect FI Pump Replace the worn out parts Assemble the FI Pump Dismantle & clean the injector & replace its worn-out parts Assemble the injector & test it to correct pressure Purpose & types of injector Parts & working of injector Pressure adjusting & testing procedure of injector Purpose & types of FI Pump Phasing & Calibrate the FI Pump & governor setting Check the injection timing by spill cut-off method Set the fuel injection timing Parts & working of FI Pump & its overhauling, phasing & calibration Function & types of Governor Functional parts of Governor ( pneumatic, RSV & RQV ) Principle of operation of mech. Operated low load advance system 30

31 Prepare the engine for starting Start & stop the engine Identify the sensors & actuators in MPFI system. Troubleshooting - Using the engine scanner, Principle of operation of solenoid operated low load advance system Causes & remedies of FI Pump Working of MPFI system. Practical Theory Inflate the wheel to recommended pressure Fit the wheel on vehicle Remove front axle of the vehicle Replace king pin bushes and hub bearings Check adjust kingpin play Adjust hub end play Remove, inspect the shock absorbers and re-fit Check and adjust turning angle Importance of tyre inflation to the recommended pressure Importance & method of tyre rotation Types of axles & hubs. Function & working of steering system and power assisted steering system Ackerman geometry of steering. Align the steering wheel with front wheel Dismantle, inspect & assemble the steering gear box Adjust pre-loading in steering gear box & re-fit Check toe-in & toe-out, Check chamber & caster angle Check king pin inclination & wheel run-out Bleed air in power assisted steering Check and adjust wheel alignment and balancing Rectify hard steering Rectify trouble of vehicle s pulling to one side Functional parts of steering geometry Types of steering gear box Importance of camber, castor & king pin inclination Purpose of wheel track & wheel base Function of toe-in & toe-out 31

32 II) OBJECTIVE: To carry out Servicing & overhauling of FI Pump To learn Electronics circuits used in automobile. To learn the working of MPFI system. To learn about air bleeding To carry out inflation of tyre & tube To check and adjust steering geometry To learn the function & types of steering system To know the need and significance of steering geometry III) ACHIEVEMENT After completion of Course, the trainee will be able to: Know about FIPs, feed pumps, injectors, phasing & calibration know the importance of tyre rotation & inflation know about steering geometry learn dismantling and assembling of steering gear box check toe-in & toe-out, camber & caster angle. Know about MPFI system 32

33 IV) TOOLS, MACHINERY, EQUIPMENTS etc. for a batch of 16 trainees Sl Item Qty Sl Item Qty a) TRAINEES TOOL KIT 20 Prick punch 15 cm. 2 s. 01 Steel rule 15 cm. English and metric 17 s 21 Chisels cross cut 200 mm X 6mm 2 s. 02 Screw driver 20cm.X 9mm. Blade 17 s 22 Allen Key set of 12 pieces (2mm to 14mm) 04Sets 03 Screw driver 30 cm. X 9 mm. Blade 17 s 23 Philips Screw Driver Type set of 5 pieces (100mm to Sets mm) 04 Spanner D.E. set of 12 pieces (6mml to 32mm) 17 s 24 Engineer s square 15 cm. Blade 2 s. 05 Pliers combination 20 cm. 17 s 25 Dividers spring 15 cm. 2 s. 06 Pliers side cutting 15 cm 17 s 26 Ball peen Hammer 0.5kg. 16 s. 07 Plier round nose 15 cm 17 s 27 Scriber with scribing black universal Plier flat nose 15 cm 17 s 28 Marking out table 90X60X90 cm. 1 s. 09 Hand file 20 cm. Second cut flat 17 s 29 Hacksaw frame adjustable Hand file 20 cm. Second cut half-round 17 s 30 Mechanic stethoscope 1 s. 11 Hand file 20 cm. smooth triangular 17 s 31 Hand vice 37 mm 2 s. 12 Hand file 30 cm. bastard 17 s 32 Drill Twist (assorted) 10 s 13 Hand file 30 cm. round bastard 17 s 33 Taps and Dies complete sets ( 5 types ) 1 set 14 Centre punch 10 cm. 17 s 34 Hand reamers adjustable 10.5 to mm, to 2 Sets mm, to mm and to mm 15 Chisel cold flat 20 mm. 17 s 35 Micrometer out side 0-25 mm, mm 1 each 16 Feeler gauge 20 blades (metric) 17 s 36 Micrometer out side 50 mm to 75mm and 75 mm to each mm. 17 Steel tools box with lock and key (folding type) size 400X200X150mm 17 s 37 Mallets wooden/plastic. 2 s. b) SHOP OUTFIT & MEASURING INSTRUMENTS 38 Micrometer in side 25-50, 50-75, mm with 1 each extension rod. 18 Hollow punch set of seven pieces 6mm to 15mm 1 Set. 39 Spanner, ring set of 12 metric sizes 6 to 32 mm. 2 s. 19 Drift punch copper 15 cm 2 s. 40 Spanner, adjustable 15cm

34 Sl Item Qty Sl Item Qty 41 Spanner for spark plugs 14mm. 2 s. 63 Horses and wheel choke 4 s. each 42 Spanners socket with speed handle, T-bar, ratchet and universal upto 32 mm Bearing puller screw powered/hydraulic powered with attachments Max spread 80, 200 and 300mm 1 Each. 43 Adjustable spanner (pipe wrench 350 mm) 2 s. 65 Hydraulic jack with trolley capacity 3 Ton Oil can 0.5/0.25 liter capacity Screw jack one tone, capacity double lift 2 s. 45 Cleaning Tray 45x30 cm. 4 s. 67 Fuel feed pump ( plunger type ) Injector cleaning Kit 2 Kits. 68 Injectors 2 s. 47 Injector dismantling and assembling jig and fixture 1 Kit 69 Surface Plate 60 x 60cm Injector dismantling tool kit 1 Kit 70 V Block 75 x 38mm pair with Clamps 2 s. 49 Fuel injection pump dismantling tool kit 1 Kit 71 Electric pedestal grinder with two 18cm. Wheel Torque wrench 12-68Nm Wheel alignment gauge 1 set 51 Work bench 250 x 120 x 60 cm with 2 vices 12cm Jaw 2 s. 73 Camber angle gauge Pullers screw powered 2 mm gap with bearing puller attachment Fuel injection pump one with pneumatic governor, one with R.Q.V. governor and one with R.S.V. governor, VE 1 Each pump / DPC pumps 53 Vice grip pliers 2 s. 75 Wheel balancing machine with accessory 1 set 54 Circlip pliers Expanding and contracting type 15cm & 20cm 8 Sets. 76 Injector testing set (hand operated) Inspection lamp with guard and wandering lead of 50ft. length Triple leg grip puller with bearings attachment screw/ hydraulic Powered max. spread 80, 160, 250, 450 mm Crow bar Fuel injector cleaning kit (in a wooden box complete) 4 Sets. 57 Cleaning tray- Aluminum 45 x 30 cm with 6 small 8 s. 79 Engines 4 cylinder petrol MPFI and four cylinder diesel 2s. compartments engine other than procured under module 01 and Portable electric drill 6mm Toe-in, toe-out gauge Circlip pliers 15 cm. Expanding type Injector dismantling jig with mounting bench Circlip pliers 15 cm. Contracting type Speed counter pointed type to read up to 5000 RPM 1. c) GENERAL INSTALLATION / MACHINERIES 83 Special tools for overhauling of inline and distributer 1 set type pumps with jigs 61 Drilling machine bench to drill up to 12mm die Fuel injection pump test bench with accessories Chain and pulley block 3000 kg. Capacity electric type 1. NOTE : All the tools and equipment etc should be Latest available in the Market 34

35 Workshop furniture Qty Suitable Work Tables with vices As required. Stools 17 s Discussion Table 1 Tool Cabinet 2 s Trainees locker 2 s Fire fighting equipment, first aid box etc As required Book shelf ( glass panel ) 1. Storage Rack As required Storage shelf As required 35

36 UPGRADATION OF ITIs into CENTERS of EXCELLENCE (CoE) ADVANCED MODULES IN II YEAR ( FOR THE FIRST 6 MONTHS OF II YEAR ) MODULE AAT - 05 : DENTING PAINTING & WELDING ( Duration - 26 weeks ) 36

37 I) COURSE CONTENT Practical Theory Dismantle body Checking & repairing of body shell Checking & repairing of front door, rear floor & wheel boxes Safety measures during denting painting & welding Different type of structure of vehicle Introduction & function of body & panels Function & types of frames. Types and uses of sander. Dry and wet sander. Denting procedure. Checking & repairing of right side & left side panel with fender Checking & repairing of roof panel & rear lower panel Touch up work on the body of vehicle Anti-rusted treatment under body of vehicle. Body prepare coating. Surface application. Putty / filling applications. Preparation of body before painting Use of different types of sanders ( Sand type ). Priming Paint application. Clear coat application. Rubbing and polishing application. Body construction, on crash repair system & alignment Painting an accidental vehicle Checking frame alignment ( car o liner ) Method & types of painting. 37

38 Fixation of wind screen glass. Masking of non-painting area. Paint protection treatment. Method of fixation of wind screen glass. Practical Theory Practice on gas welding, gas brazing & gas soldering Practice on arc welding GAS WELDING : - Gas Welding, brazing & Soldering procedures Gas cutting practice ARC WELDING : - Basic Electricity and welding power source Electrodes types, description & Specification Arc Welding procedure Practice on MIG / MAG welding Practice on TIG welding Practice on Resistance spot welding Practice on plastic welding MIG / MAG WELDING: - Principles of MIG/MAG Welding MIG Welding Procedure TIG WELDING: - Introduction to TIG Welding Methods of Welding RESISTANCE & PLASTIC WELDING :- Resistance welding process spot, seam and Butt welding. Plastic welding procedure II) OBJECTIVE: To learn major assembly of vehicle Safety measures during operation To learn function & types of frame To learn body construction & repair To learn body paint with different methods 38

39 Low-pressure, high-pressure & setting up of oxy acetylene equipment Flame adjustment as per requirement Selection of filler rod as per requirement Application of filler metal on required area Arc welding Setting up of arc, spot and MIG welding equipment Selection of electrode as per requirement Arc striking and maintaining Depositing metal by various size beads Gas tungsten arc welding Setting up of G.T.A.W machine & equipment Selection of filler metal as per job Depositing metal as per requirement Plastic welding Setting up of plastic welding equipment Selection of filler metal as per requirement Welding of plastic parts as per requirement III) ACHIEVEMENT After completion of Course, the trainee will be able to:. know the repair of vehicle body know the painting of vehicle body know about welding of various parts 39